Three-dimensional shaped article production method

ABSTRACT

A three-dimensional shaped article production method for producing a three-dimensional shaped article by stacking layers to form a stacked body includes a first layer formation step of forming a first layer on a support by supplying a first composition containing first particles and a binder, a second layer formation step of forming a second layer composed of one layer or a plurality of layers on the first layer by supplying a second composition containing second particles and a binder, and a separation step of separating the second layer from the support through the first layer, wherein after the separation step, a sintering step of sintering the second layer is performed.

This application is a continuation of U.S. patent application Ser. No.15/411,587, filed Jan. 20, 2017, which claims priority to Japanesepatent No. 2016-010395, filed Jan. 22, 2016, the entire disclosures ofwhich are expressly incorporated by reference herein.

BACKGROUND 1. Technical Field

The present invention relates to a three-dimensional shaped articleproduction method.

2. Related Art

In the related art, production methods for producing a three-dimensionalshaped article by stacking layers have been performed. Among these, athree-dimensional shaped article production method in which athree-dimensional shaped article is formed on a support has beendisclosed.

For example, JP-A-2000-73108 (Patent Document 1) discloses athree-dimensional shaped article production method in which athree-dimensional shaped article is formed on an up-and-down table as asupport while sintering a metal powder layer.

However, in a three-dimensional shaped article production method inwhich a three-dimensional shaped article is formed on a support asdisclosed in Patent Document 1, a sintered body of the three-dimensionalshaped article is integrated with the support, or the like, andtherefore, it is difficult to separate the sintered body of thethree-dimensional shaped article from the support.

SUMMARY

An advantage of some aspects of the invention is to reduce the load whena three-dimensional shaped article is separated from a support.

A three-dimensional shaped article production method according to afirst aspect of the invention is a three-dimensional shaped articleproduction method for producing a three-dimensional shaped article bystacking layers to form a stacked body and includes a first layerformation step of forming a first layer on a support by supplying afirst composition containing first particles and a binder, a secondlayer formation step of forming a second layer composed of one layer ora plurality of layers on the first layer by supplying a secondcomposition containing second particles and a binder, and a separationstep of separating the second layer from the support through the firstlayer, wherein after the separation step, a sintering step of sinteringthe second layer is performed.

According to this aspect of the invention, after the separation step ofseparating the second layer from the support, the sintering step ofsintering the second layer is performed. Therefore, the integration orthe like of the sintered body of the three-dimensional shaped articlewith the support can be suppressed, and the load when thethree-dimensional shaped article is separated from the support can bereduced.

A three-dimensional shaped article production method according to asecond aspect of the invention is directed to the first aspect, in whicha binding force between the first particles by the binder contained inthe first composition is smaller than a binding force between the secondparticles by the binder contained in the second composition.

According to this aspect, a binding force between the first particles bythe binder contained in the first composition is smaller than a bindingforce between the second particles by the binder contained in the secondcomposition. Therefore, when the second layer (a stacked body of thethree-dimensional shaped article) is separated from the support in theseparation step, the second layer is easily separated from the supportwithout damaging the three-dimensional shaped article.

A three-dimensional shaped article production method according to athird aspect of the invention is directed to the second aspect, in whichthe amount of the binder contained in the first composition is smallerthan the amount of the binder contained in the second composition.

According to this aspect, the amount of the binder contained in thefirst composition is smaller than the amount of the binder contained inthe second composition. Therefore, a binding force between the firstparticles by the binder contained in the first composition can be madesmaller than a binding force between the second particles by the bindercontained in the second composition. As a result, when the second layer(a stacked body of the three-dimensional shaped article) is separatedfrom the support in the separation step, the second layer is easilyseparated from the support without damaging the three-dimensional shapedarticle.

A three-dimensional shaped article production method according to afourth aspect of the invention is directed to any one of the first tothird aspects, in which, before the separation step, a separationpromotion step of promoting the separation of the second layer from thesupport is performed.

According to this aspect, before the separation step, a separationpromotion step of promoting the separation of the second layer from thesupport is performed. Therefore, the separation step can be facilitated.

A three-dimensional shaped article production method according to afifth aspect of the invention is directed to the fourth aspect, in whichthe decomposition temperature of the binder contained in the firstcomposition is lower than the decomposition temperature of the bindercontained in the second composition, and the separation promotion stepis a heating step of performing heating at a temperature higher than thedecomposition temperature of the binder contained in the firstcomposition and lower than the decomposition temperature of the bindercontained in the second composition.

According to this aspect, the separation promotion step is a heatingstep of performing heating at a temperature higher than thedecomposition temperature of the binder contained in the firstcomposition and lower than the decomposition temperature of the bindercontained in the second composition. Therefore, the separation promotionstep can be performed easily.

A three-dimensional shaped article production method according to asixth aspect of the invention is directed to the fourth aspect, in whichthe support is configured to be capable of transmitting anelectromagnetic wave, and the separation promotion step is anelectromagnetic wave irradiation step of irradiating the firstcomposition with an electromagnetic wave through the support.

According to this aspect, the separation promotion step is anelectromagnetic wave irradiation step of irradiating the firstcomposition with an electromagnetic wave through the support. Therefore,the separation promotion step can be performed easily.

A three-dimensional shaped article production method according to aseventh aspect of the invention is directed to the sixth aspect, inwhich a titania layer is formed on the support.

According to this aspect, a titania layer is formed on the support. Thebinder which is in contact with the titania layer is easily decomposedby irradiation with an electromagnetic wave, and therefore, in theseparation step, the separation of the second layer from the support canbe particularly easily performed through the titania layer.

A three-dimensional shaped article production method according to aneighth aspect of the invention is directed to any one of the first toseventh aspects, in which the arithmetic average surface roughness Ra ofthe support is 5 μm or less.

According to this aspect, the arithmetic average surface roughness Ra ofthe support is 5 μm or less. That is, the surface of the support issmooth. Therefore, the occurrence of an anchor effect or the like on thesupport can be suppressed, and in the separation step, the separation ofthe second layer from the support can be particularly easily performed.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described with reference to the accompanyingdrawings, wherein like numbers reference like elements.

FIG. 1A is a schematic configuration view showing a configuration of athree-dimensional shaped article production apparatus according to anembodiment of the invention, and FIG. 1B is an enlarged view of aportion C shown in FIG. 1A.

FIG. 2A is a schematic configuration view showing a configuration of athree-dimensional shaped article production apparatus according to anembodiment of the invention, and FIG. 2B is an enlarged view of aportion C′ shown in FIG. 2A.

FIG. 3 is a schematic perspective view of a head base according to anembodiment of the invention.

FIGS. 4A to 4C are plan views conceptually illustrating the relationshipbetween the arrangement of head units and the form of formation of athree-dimensional shaped article according to an embodiment of theinvention.

FIGS. 5A and 5B are schematic views conceptually illustrating the formof formation of a three-dimensional shaped article.

FIGS. 6A and 6B are schematic views showing examples of otherarrangements of head units arranged in a head base.

FIGS. 7A to 7F are schematic views showing a three-dimensional shapedarticle production process according to an embodiment of the invention.

FIG. 8 is a flowchart showing a three-dimensional shaped articleproduction method according to an embodiment of the invention.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

Hereinafter, embodiments according to the invention will be describedwith reference to the accompanying drawings.

FIGS. 1A to 2B are schematic configuration views showing a configurationof a three-dimensional shaped article production apparatus according toan embodiment of the invention.

Here, the three-dimensional shaped article production apparatusaccording to this embodiment includes two material supply sections (headbases) and one heating section. Among these, FIGS. 1A and 1B are viewsshowing only one material supply section (a material supply sectionwhich supplies a constituent material (a material containing particlesconstituting a three-dimensional shaped article, a solvent, and abinder)). FIGS. 2A and 2B are views showing one material supply section(a material supply section which supplies a support layer formingmaterial for forming a support layer that supports a three-dimensionalshaped article when the three-dimensional shaped article is formed) andone heating section (a heating section using a laser for sintering thesupport layer forming material).

The “three-dimensional shaping” as used herein refers to the formationof a so-called “three-dimensional shaped article”, and also includes,for example, the formation of a shape with a thickness even if the shapeis a plate shape or a so-called two-dimensional shape. Further, the“supporting” as used herein includes supporting from the lower side, andin addition thereto, also includes supporting from the lateral side, andin some cases, supporting from the upper side.

A three-dimensional shaped article production apparatus 2000(hereinafter referred to as “forming apparatus 2000”) shown in FIGS. 1Ato 2B includes a base 110 and a stage 120 which is provided movably inthe X, Y, and Z directions shown in the drawing or drivably in thedirection of rotation about the Z axis by a drive device 111 as a driveunit provided for the base 110.

Then, as shown in FIGS. 1A and 1B, the three-dimensional shaped articleproduction apparatus 2000 includes a head base support section 130, oneend of which is fixed to the base 110, and to the other end of which, ahead base 1100 that holds a plurality of head units 1400 each includinga constituent material ejection section 1230 that ejects a constituentmaterial is held and fixed.

Further, as shown in FIGS. 2A and 2B, the three-dimensional shapedarticle production apparatus 2000 includes a head base support section730, one end of which is fixed to the base 110, and to the other end ofwhich, a head base 1600 that holds a plurality of head units 1900 eachincluding a support layer forming material ejection section 1730 thatejects a material for forming a support layer that supports athree-dimensional shaped article is held and fixed.

Here, the head base 1100 and the head base 1600 are provided in parallelin the XY plane.

The constituent material ejection section 1230 and the support layerforming material ejection section 1730 have the same configuration.However, the configuration is not limited thereto.

On the stage 120, layers 501, 502, and 503 are formed in the process forforming a three-dimensional shaped article 500. In the formation of thethree-dimensional shaped article 500, thermal energy is applied by alaser or the like, and therefore, in order to protect the stage 120 fromheat, by using a sample plate 121 having heat resistance, thethree-dimensional shaped article 500 may be formed on the sample plate121. The sample plate 121 of this embodiment is made of a metal so thatit is sturdy and can make the surface smooth (capable of producing thethree-dimensional shaped article 500 with higher accuracy) and also iseasily produced. However, as the sample plate 121, for example, by usinga ceramic plate, high heat resistance can be obtained, and also thereactivity with the constituent material of the three-dimensional shapedarticle to be melted (or which may be sintered) is low, and thus,alteration of the three-dimensional shaped article 500 can be prevented.Incidentally, in FIGS. 1A and 2A, for the sake of convenience ofexplanation, three layers: the layers 501, 502, and 503 are shown asexamples, however, the layers (up to the layer 50 n in FIGS. 1A and 2A)are stacked until the desired shape of the three-dimensional shapedarticle 500 is obtained. In this manner, in the forming apparatus 2000of this embodiment, the three-dimensional shaped article 500 can beformed by using the sample plate 121, and also the three-dimensionalshaped article 500 can be formed without using the sample plate 121.Therefore, either of the stage 120 and the sample plate 121 can serve asthe support when forming the three-dimensional shaped article 500.However, in the following description, a case where thethree-dimensional shaped article 500 is formed using the sample plate121 is assumed and described.

Here, the layer 501 is a so-called release layer, and is constituted bya support layer 300 formed from a support layer forming material ejectedfrom the support layer forming material ejection section 1730. The layer501 is a first layer S1 formed by supplying the support layer formingmaterial as a first composition containing first particles and a binderonto the support (see FIG. 7A).

Further, the layers 502, 503, . . . , and 50 n are each constituted by asupport layer 300 formed from the support layer forming material ejectedfrom the support layer forming material ejection section 1730 and aconstituent layer 310 formed from the constituent material ejected fromthe constituent material ejection section 1230. In other words, thelayers 502, 503, . . . , and 50 n are a second layer S2 composed of onelayer or a plurality of layers formed by supplying the constituentmaterial as a second composition containing second particles and abinder onto the layer 501 as the first layer S1 (see FIGS. 7B to 7E).

FIG. 1B is an enlarged conceptual view of a portion C showing the headbase 1100 shown in FIG. 1A. As shown in FIG. 1B, the head base 1100holds a plurality of head units 1400. Although a detailed descriptionwill be given later, each head unit 1400 is configured such that theconstituent material ejection section 1230 included in a constituentmaterial supply device 1200 is held by a holding jig 1400 a. Theconstituent material ejection section 1230 includes an ejection nozzle1230 a and an ejection drive section 1230 b that allows the constituentmaterial to be ejected from the ejection nozzle 1230 a by a materialsupply controller 1500.

FIG. 2B is an enlarged conceptual view of a portion C′ showing the headbase 1600 shown in FIG. 2A. As shown in FIG. 2B, the head base 1600holds a plurality of head units 1900. Each head unit 1900 is configuredsuch that the support layer forming material ejection section 1730included in a support layer forming material supply device 1700 is heldby a holding jig 1900 a. The support layer forming material ejectionsection 1730 includes an ejection nozzle 1730 a and an ejection drivesection 1730 b that allows the support layer forming material to beejected from the ejection nozzle 1730 a by the material supplycontroller 1500. Further, in the case where a material which can besintered is used as the support layer forming material, a laserirradiation section 3100 for sintering the support layer formingmaterial and a galvanometer mirror 3000 which determines the position ofthe laser light from the laser irradiation section 3100 are provided onthe upper side of the stage 120.

As shown in FIGS. 1A and 1B, the constituent material ejection section1230 is connected to a constituent material supply unit 1210 whichhouses a constituent material made to correspond to each head unit 1400held by the head base 1100 through a supply tube 1220. Then, a givenconstituent material is supplied to the constituent material ejectionsection 1230 from the constituent material supply unit 1210. In theconstituent material supply unit 1210, the constituent material of thethree-dimensional shaped article 500 to be shaped by the formingapparatus 2000 according to this embodiment is housed in a constituentmaterial housing section 1210 a, and each individual constituentmaterial housing section 1210 a is connected to each individualconstituent material ejection section 1230 through the supply tube 1220.In this manner, by including the individual constituent material housingsections 1210 a, a plurality of different types of materials can besupplied from the head base 1100.

As shown in FIGS. 2A and 2B, the support layer forming material ejectionsection 1730 is connected to a support layer forming material supplyunit 1710 which houses a support layer forming material made tocorrespond to each head unit 1900 held by the head base 1600 through asupply tube 1720. Then, a given support layer forming material issupplied to the support layer forming material ejection section 1730from the support layer forming material supply unit 1710. In the supportlayer forming material supply unit 1710, the support layer formingmaterial constituting a support layer when shaping the three-dimensionalshaped article 500 is housed in a support layer forming material housingsection 1710 a, and each individual support layer forming materialhousing section 1710 a is connected to each individual support layerforming material ejection section 1730 through the supply tube 1720. Inthis manner, by including the individual support layer forming materialhousing sections 1710 a, a plurality of different types of materials canbe supplied from the head base 1600.

Examples of the support layer forming material and the constituentmaterial (the materials of the first particles and the second particles)include simple substance powders of magnesium (Mg), iron (Fe), cobalt(Co), chromium (Cr), aluminum (Al), titanium (Ti), copper, (Cu), andnickel (Ni), alloys containing at least one metal among these (amaraging steel, stainless steel, cobalt-chrome-molybdenum, a titaniumalloy, a nickel alloy, an aluminum alloy, a cobalt alloy, and acobalt-chrome alloy), various metal oxides such as silica, alumina,titanium oxide, zinc oxide, zircon oxide, tin oxide, magnesium oxide,and potassium titanate, various metal hydroxides such as magnesiumhydroxide, aluminum hydroxide, and calcium hydroxide, various metalnitrides such as silicon nitride, titanium nitride, and aluminumnitride, various metal carbides such as silicon carbide and titaniumcarbide, various metal sulfides such as zinc sulfide, various metalcarbonates such as calcium carbonate and magnesium carbonate, variousmetal sulfates such as calcium sulfate and magnesium sulfate, variousmetal silicates such as calcium silicate and magnesium silicate, variousmetal phosphates such as calcium phosphate, various metal borates suchas aluminum borate and magnesium borate, composite compounds and thelike thereof, and gypsum (various hydrates of calcium sulfate andanhydrous calcium sulfate).

A mixed powder of these materials can be used by being mixed with asolvent and a binder to form a mixed material or the like in the form ofa slurry (or a paste).

It is also possible to use general purpose engineering plastics such aspolyamide, polyacetal, polycarbonate, modified polyphenylene ether,polybutylene terephthalate, and polyethylene terephthalate. In additionthereto, it is also possible to use engineering plastics such aspolysulfone, polyethersulfone, polyphenylene sulfide, polyarylate,polyimide, polyamideimide, polyetherimide, and polyether ether ketone.

In this manner, the constituent material and the support layer formingmaterial are not particularly limited, and a metal other than theabove-mentioned metals, a ceramic, a resin, or the like can also beused.

Examples of the solvent include water; (poly) alkylene glycol monoalkylethers such as ethylene glycol monomethyl ether, ethylene glycolmonoethyl ether, propylene glycol monomethyl ether, and propylene glycolmonoethyl ether; acetate esters such as ethyl acetate, n-propyl acetate,iso-propyl acetate, n-butyl acetate, and iso-butyl acetate; aromatichydrocarbons such as benzene, toluene, and xylene; ketones such asmethyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl n-butylketone, diisopropyl ketone, and acetyl acetone; alcohols such asethanol, propanol, and butanol; tetra-alkyl ammonium acetates;sulfoxide-based solvents such as dimethyl sulfoxide and diethylsulfoxide; pyridine-based solvents such as pyridine, γ-picoline, and2,6-lutidine; and ionic liquids such as tetra-alkyl ammonium acetate(for example, tetra-butyl ammonium acetate, etc.), and one type or twoor more types in combination selected from these can be used.

As the binder, for example, an acrylic resin, an epoxy resin, a siliconeresin, a cellulosic resin, or another synthetic resin, or PLA(polylactic acid), PA (polyamide), PPS (polyphenylene sulfide), PVDF(polyvinylidene fluoride), CMC (carboxymethyl cellulose), or anotherthermoplastic resin can be used.

The forming apparatus 2000 includes a control unit 400 as a controldevice which controls the stage 120, the constituent material ejectionsection 1230 included in the constituent material supply device 1200,and the support layer forming material ejection section 1730 included inthe support layer forming material supply device 1700 based on the datafor shaping a three-dimensional shaped article to be output from a dataoutput device such as, for example, a personal computer (not shown) orthe like. The control unit 400 includes a control section (not shown)which controls the stage 120 and the constituent material ejectionsection 1230 so that these members are driven and operated incooperation with each other, and also controls the stage 120 and thesupport layer forming material ejection section 1730 so that thesemembers are driven and operated in cooperation with each other.

The stage 120 provided movably for the base 110, and a signal forcontrolling the start and stop of movement, the direction of movement,the amount of movement, the speed of movement, or the like of the stage120 is generated in a stage controller 410 based on a control signalfrom the control unit 400 and sent to the drive device 111 included inthe base 110, and the stage 120 moves in the X, Y, or Z direction shownin the drawing. In the constituent material ejection section 1230included in the head unit 1400, a signal for controlling the amount ofthe material ejected from the ejection nozzle 1230 a in the ejectiondrive section 1230 b included in the constituent material ejectionsection 1230 or the like is generated in the material supply controller1500 based on a control signal from the control unit 400, and apredetermined amount of the constituent material is ejected from theejection nozzle 1230 a based on the generated signal.

In the same manner, in the support layer forming material ejectionsection 1730 included in the head unit 1900, a signal for controllingthe amount of the material ejected from the ejection nozzle 1730 a inthe ejection drive section 1730 b included in the support layer formingmaterial ejection section 1730 or the like is generated in the materialsupply controller 1500 based on a control signal from the control unit400, and a predetermined amount of the support layer forming material isejected from the ejection nozzle 1730 a based on the generated signal.

Next, the head unit 1400 will be described in further detail. The headunit 1900 has the same configuration as that of the head unit 1400, andtherefore, a description of the detailed configuration of the head unit1900 will be omitted.

FIGS. 3 to 4C show one example of the holding form of a plurality ofhead units 1400 and the constituent material ejection sections 1230 heldby the head base 1100, and among these, FIGS. 4A to 4C are externalviews of the head base 1100 viewed from the direction of the arrow Dshown in FIG. 1B.

As shown in FIG. 3, a plurality of head units 1400 are held by the headbase 1100 through a fixing unit (not shown). Further, as shown in FIGS.4A to 4C, in the head base 1100 of the forming apparatus 2000 accordingto this embodiment, the head units 1400 are included such that thefollowing 4 units: a head unit 1401 in the first row from the lower sidein the drawing, a head unit 1402 in the second row, a head unit 1403 inthe third row, and a head unit 1404 in the fourth row are arranged in astaggered manner (alternately). Then, as shown in FIG. 4A, while movingthe stage 120 in the X direction with respect to the head base 1100, theconstituent material is ejected from each head unit 1400, wherebyconstituent layer constituting parts 50 (constituent layer constitutingparts 50 a, 50 b, 50 c, and 50 d) are formed. The procedure for formingthe constituent layer constituting parts 50 will be described later.

Incidentally, although not shown in the drawing, the constituentmaterial ejection sections 1230 included in the respective head units1401 to 1404 are configured to be connected to the constituent materialsupply unit 1210 through the ejection drive section 1230 b with thesupply tube 1220.

As shown in FIG. 3, the constituent material ejection section 1230ejects a material M which is the constituent material of thethree-dimensional shaped article from the ejection nozzle 1230 a to thelayer 501 (the support layer 300 as the release layer) as the firstlayer S1 formed on the sample plate 121 placed on the stage 120. In thehead unit 1401, an ejection form in which the material M is ejected inthe form of a liquid droplet is illustrated, and in the head unit 1402,an ejection form in which the material M is ejected in the form of acontinuous body is illustrated. The ejection form of the material M maybe in the form of either a liquid droplet or a continuous body, however,in this embodiment, a case where a form in which the material M isejected in the form of a liquid droplet is adopted will be described.Incidentally, a supply form of the material M is not limited to such aconfiguration, and for example, a configuration in which a material inthe form of a solid at normal temperature is converted into a liquid byheating and ejected, or the like may be adopted.

The material M ejected in the form of a liquid droplet from the ejectionnozzle 1230 a flies substantially in the direction of gravity and landson the sample plate 121. The stage 120 moves, and by the material Mlanding on the sample plate 121, the constituent layer constitutingparts 50 are formed. An assembly of the constituent layer constitutingparts 50 is formed as the layer 502 constituting the second layer S2 orthe constituent layer 310 of the three-dimensional shaped article 500.

Next, the procedure for forming the constituent layer constituting parts50 will be described with reference to FIGS. 4A to 5B.

FIGS. 4A to 4C are plan views conceptually illustrating the relationshipbetween the arrangement of head units 1400 of this embodiment and theform of formation of the constituent layer constituting parts 50. FIGS.5A and 5B are side views conceptually illustrating the form of formationof the constituent layer constituting parts 50.

First, when the stage 120 moves in the +X direction, the material M isejected in the form of a liquid droplet from the plurality of ejectionnozzles 1230 a, and the material M is placed at a predetermined positionon the sample plate 121, and therefore, the constituent layerconstituting parts 50 are formed.

More specifically, first, as shown in FIG. 5A, while moving the stage120 in the +X direction, the material M is placed at predeterminedpositions at regular intervals on the sample plate 121 from theplurality of ejection nozzles 1230 a.

Subsequently, as shown in FIG. 5B, while moving the stage 120 in the −Xdirection shown in FIG. 1A, the material M is newly placed so as to fillthe gap between the materials M placed at regular intervals.

However, a configuration in which while moving the stage 120 in the +Xdirection, the materials Mare ejected from the plurality of ejectionnozzles 1230 a so that the materials M overlap with each other (so asnot to form a gap) at predetermined positions on the sample plate 121(not a configuration in which the constituent layer constituting parts50 are formed by the reciprocation of the stage 120 in the X direction,but a configuration in which the constituent layer constituting parts 50are formed by only one way movement of the stage 120 in the X direction)may be adopted.

By forming the constituent layer constituting parts 50 as describedabove, the constituent layer constituting parts 50 (the constituentlayer constituting parts 50 a, 50 b, 50 c, and 50 d) for one line (ofthe first line in the Y direction) in the X direction of the respectivehead units 1401, 1402, 1403, and 1404 as shown in FIG. 4A are formed.

Subsequently, in order to form constituent layer constituting parts 50′(constituent layer constituting parts 50 a′, 50 b′, 50 c′, and 50 d′) ofthe second line in the Y direction of the respective head units 1401,1402, 1403, and 1404, the head base 1100 is moved in the −Y direction.As for the amount of movement, when the pitch between the nozzles isrepresented by P, the head base 1100 is moved in the −Y direction by adistance of P/n (n represents a natural number). In this embodiment, adescription will be given by assuming that n is 3.

By performing the same operation as described above as shown in FIGS. 5Aand 5B, the constituent layer constituting parts 50′ (constituent layerconstituting parts 50 a′, 50 b′, 50 c′, and 50 d′) of the second line inthe Y direction as shown in FIG. 4B are formed.

Subsequently, in order to form constituent layer constituting parts 50″(constituent layer constituting parts 50 a″, 50 b″, 50 c″, and 50 d″) ofthe third line in the Y direction of the respective head units 1401,1402, 1403, and 1404, the head base 1100 is moved in the −Y direction.As for the amount of movement, the head base 1100 is moved in the −Ydirection by a distance of P/3.

Then, by performing the same operation as described above as shown inFIGS. 5A and 5B, the constituent layer constituting parts 50″(constituent layer constituting parts 50 a″, 50 b″, 50 c″, and 50 d″) ofthe third line in the Y direction as shown in FIG. 4C are formed, andthus, the constituent layer 310 can be obtained.

Further, as for the material M ejected from the constituent materialejection section 1230, from any one unit or two or more units of thehead units 1401, 1402, 1403, and 1404, a constituent material differentfrom the other head units can also be ejected and supplied. Therefore,by using the forming apparatus 2000 according to this embodiment, athree-dimensional shaped article formed from different materials canalso be obtained.

Further, by ejecting the support layer forming material from the supportlayer forming material ejection section 1730, the support layer 300 canbe formed as the layer 501 which is the first layer S1 in the samemanner as described above. Then, on the layer 501 which is the firstlayer S1, the constituent layer 310 and the support layer 300 can beformed in the same manner as described above when the layers 502, 503, .. . , and 50 n which are the second layer S2 are formed. The supportlayer 300 can be sintered or the like using the laser irradiationsection 3100 and the galvanometer mirror 3000 according to the type ofthe support layer forming material.

The number and arrangement of the head units 1400 and 1900 included inthe forming apparatus 2000 according to this embodiment described aboveare not limited to the above-mentioned number and arrangement. FIGS. 6Aand 6B schematically show examples of other arrangement of the headunits 1400 placed in the head base 1100.

FIG. 6A shows a form in which a plurality of head units 1400 arearranged in parallel in the X-axis direction in the head base 1100. FIG.6B shows a form in which the head units 1400 are arranged in a latticein the head base 1100. The number of the head units to be arranged isnot limited to the examples shown in FIGS. 6A and 6B.

Next, one embodiment of a three-dimensional shaped article productionmethod to be performed using the above-mentioned forming apparatus 2000according to this embodiment will be described.

FIGS. 7A to 7F are schematic views showing one example of athree-dimensional shaped article production process to be performedusing the above-mentioned forming apparatus 2000. FIGS. 7A to 7F showthe three-dimensional shaped article production process viewed from theside.

First, FIG. 7A shows a state where the support layer 300 as a releaselayer is formed as the first layer S1 on the sample plate 121 using thesupport layer forming material ejection section 1730. In thisembodiment, as the support layer forming material, a material containingceramic particles as the first particles and a resin as the binder isused. In this embodiment, as the ceramic particles, particles in aspherical shape are used, however, the shape thereof may be a needleshape, a fibrous shape, a leaf shape, or the like.

Here, FIG. 7A shows a state where the support layer forming material isejected from the support layer forming material ejection section 1730and also a laser from the laser irradiation section 3100 is irradiatedonto the support layer forming material. The ceramic particles as thefirst particles are not sintered by the irradiation with the laser, andare in a state where since the binder is left in the support layer 300,the particles on the sample plate 121 are bound to one another.Incidentally, the laser irradiation conditions may be appropriatelychanged according to the type or amount of the resin as the binder, orin the case where a solvent is contained in the support layer formingmaterial, the solvent may be evaporated by irradiation with a laser.

Subsequently, FIG. 7B shows a state where the support layer 300 isformed in a region (three-dimensional shaped article non-formationregion) other than the three-dimensional shaped article formation regionon the support layer 300 as the first layer S1 using the support layerforming material ejection section 1730.

Subsequently, FIG. 7C shows a state where the constituent layer 310 isformed as the second layer S2 in the three-dimensional shaped articleformation region on the support layer 300 as the first layer S1 usingthe constituent material ejection section 1230. In this embodiment, asthe constituent material, a material containing metal particles as thesecond particles and a resin as the binder is used. Here, the type andamount of the respective resins is adjusted so that the binding forcebetween the metal particles by the resin contained in the constituentmaterial is larger than the binding force between the ceramic particlesby the resin contained in the support layer forming material. In thecase where a solvent is contained in the constituent material, thesolvent may be evaporated by irradiation with a laser under theconditions that the metal particles are not sintered.

Then, by repeating the formation of the support layer 300 shown in FIG.7B and the formation of the constituent layer 310 shown in FIG. 7C, astacked body of the three-dimensional shaped article is formed as shownin FIG. 7D.

Here, FIG. 7E shows a state where the stacked body of thethree-dimensional shaped article (the second layer S2) formed as shownin FIG. 7D is released from the sample plate 121. In FIG. 7E, a statewhere the support layer 300 as the first layer S1 and the stacked bodyof the three-dimensional shaped article (the second layer S2) arereleased from each other is shown, however, the sample plate 121 and thesupport layer 300 as the first layer S1 may be released from each other.Further, in a part, the support layer 300 as the first layer S1 and thestacked body of the three-dimensional shaped article (the second layerS2) may be released from each other, and in another part, the sampleplate 121 and the support layer 300 as the first layer S1 may bereleased from each other.

FIG. 7F shows a state where the constituent layers 310 in the stackedbody of the three-dimensional shaped article released from the sampleplate 121 as shown in FIG. 7E are sintered in a thermostatic chamber(heating chamber) 1800 provided separately from the forming apparatus2000 according to this embodiment. As the metal particles, particleshaving a lower melting point lower than that of the ceramic particlesare selected. Further, the sintering step is performed at a temperature,which is lower than the melting points of the metal particles and theceramic particles, and at which the metal particles are sintered, butthe ceramic particles are not sintered.

Incidentally, in FIG. 7F, as the sintering of the constituent layers 310in the stacked body of the three-dimensional shaped article proceeds,the binder component contained in the support layers 300 is decomposed(thermally decomposed), and by applying a small external force thereto,the ceramic particles are separated from each other and fall apart. Inthis embodiment, a state where the sintering is performed on a ceramicplate 1810 which has high heat resistance is shown.

Next, one example of the three-dimensional shaped article productionmethod to be performed using the above-mentioned forming apparatus 2000(an example corresponding to FIGS. 7A to 7F) will be described withreference to a flowchart.

Here, FIG. 8 is a flowchart of the three-dimensional shaped articleproduction method according to this embodiment.

As shown in FIG. 8, in the three-dimensional shaped article productionmethod according to this embodiment, first, in Step S110, the data ofthe three-dimensional shaped article is acquired. More specifically, thedata representing the shape of the three-dimensional shaped article isacquired from, for example, an application program or the like executedby a personal computer.

Subsequently, in Step S120, data for each layer are created. Morespecifically, in the data representing the shape of thethree-dimensional shaped article, the three-dimensional shaped articleis sliced according to the shaping resolution in the Z direction, andbitmap data (cross-sectional data) are created for each cross section.

At this time, the bitmap data to be created are data discriminatedbetween the three-dimensional shaped article formation region(constituent layer 310) and the three-dimensional shaped articlenon-formation region (support layer 300).

Subsequently, in Step S130, it is determined whether the data of thelayer to be formed is the data for forming the three-dimensional shapedarticle non-formation region (support layer 300) or the data for formingthe three-dimensional shaped article formation region (constituent layer310). This determination is performed by the control section included inthe control unit 400.

In this step, in the case where the data is determined to be the datafor forming the support layer 300, the process proceeds to Step S140,and in the case where the data is determined to be the data for formingthe constituent layer 310, the process proceeds to Step S150.

In Step S140, by ejecting the support layer forming material from thesupport layer forming material ejection section 1730 based on the datafor forming the support layer 300, the support layer forming material issupplied.

Here, the step of forming the layer 501 which is the first layer S1 (afirst layer formation step) corresponds to this step. However, also thestep of forming the support layer 300 in the second layer S2 (a secondlayer formation step) corresponds to this step.

Then, when the support layer forming material is ejected in Step S140, alaser is irradiated (energy is applied) from the laser irradiationsection 3100 through the galvanometer mirror 3000 in Step S160, wherebythe ejected liquid droplet (the support layer 300) is solidified.

On the other hand, in Step S150, by ejecting the constituent materialfrom the constituent material ejection section 1230, the constituentmaterial is supplied. The step of forming the layers 502, 503, . . . ,and 50 n which are the second layer S2 (a second layer formation step)corresponds to this step.

Then, the process is repeated from. Step S130 to Step S170 until it isdetermined in Step S170 that the formation of the stacked body of thethree-dimensional shaped article based on the bitmap data correspondingto the respective layers formed in Step S120 is completed.

Then, the stacked body of the three-dimensional shaped article isreleased from the sample plate 121 in Step S180, and the stacked body ofthe three-dimensional shaped article formed in the above steps is heatedin the thermostatic chamber 1800 in Step S190. More specifically, thethree-dimensional shaped article formation region (constituent layer310) is sintered.

Then, accompanying the completion of Step S190, the three-dimensionalshaped article production method of this embodiment is completed.

As described above, the three-dimensional shaped article productionmethod of this embodiment is a three-dimensional shaped articleproduction method for producing a three-dimensional shaped article bystacking layers to form a stacked body.

Then, the method includes the first layer formation step (correspondingto Step S140) of forming the first layer S1 on the sample plate 121 bysupplying the support layer forming material which is the firstcomposition containing the ceramic particles and the resin, the secondlayer formation step (corresponding to Step S150 and also Step S140 inthe case where the support layer 300 is formed in the second layer S2)of forming the second layer S2 composed of one layer or a plurality oflayers (the stacked body of the three-dimensional shaped article) on thefirst layer S1 by supplying the constituent material which is the secondcomposition containing the metal particles and the resin, and theseparation step (corresponding to Step S180) of separating the secondlayer S2 from the sample plate 121 through the first layer S1.

Then, after the separation step, the sintering step (corresponding toStep S190) of sintering the second layer S2 is performed.

In this manner, by performing the sintering step of sintering the secondlayer S2 after the separation step of separating the second layer S2from the sample plate 121, the integration or the like of the sinteredbody of the three-dimensional shaped article with the sample plate 121can be suppressed, and the load when the three-dimensional shapedarticle is separated from the sample plate 121 can be reduced.

It goes without saying that when the second layer S2 is formed, not onlythe layer is formed using the support layer forming material for formingthe support layer 300 in addition to the constituent material asdescribed above, but also the layer may be formed only from theconstituent material.

Further, in the three-dimensional shaped article production method ofthis embodiment, as described above, the binding force between theceramic particles by the resin contained in the support layer formingmaterial is adjusted to be smaller than the binding force between themetal particles by the resin contained in the constituent material.Therefore, when the second layer S2 is separated from the sample plate121 in the separation step, the second layer S2 is easily separated fromthe sample plate 121 without damaging the three-dimensional shapedarticle.

Here, as a method for adjusting the binding force between the ceramicparticles by the resin contained in the support layer forming materialto be smaller than the binding force between the metal particles by theresin contained in the constituent material, for example, a method inwhich as the binder contained in the support layer forming material andthe binder contained in the constituent material, the same binder isused, and the amount of the binder contained in the support layerforming material is made smaller than the amount of the binder containedin the constituent material can be used.

By using such a method, the binding force between the ceramic particlesby the resin contained in the support layer forming material can be madesmaller than the binding force between the metal particles by the resincontained in the constituent material. As a result, when the secondlayer S2 is separated from the support in the separation step, thesecond layer S2 is easily separated from the plate 121 without damagingthe three-dimensional shaped article.

Specifically, for example, the amount of the binder contained in thesupport layer forming material is set to 5% or more and 60% or less, andthe amount of the binder contained in the constituent material can beset larger than this.

Here, it is preferred that the surface of the plate 121 is made smoothby setting the arithmetic average surface roughness Ra of the plate 121to 5 μm or less. It is because by making the surface of the plate 121smooth, the occurrence of an anchor effect or the like on the plate 121can be suppressed, and in the separation step, the separation of thesecond layer S2 from the plate 121 can be particularly easily performed.

Further, although not performed in the three-dimensional shaped articleproduction method of this embodiment, a separation promotion step ofpromoting the separation of the second layer S2 from the plate 121 maybe performed before the separation step. This is because the separationstep can be facilitated.

For example, as the binders contained in the support layer formingmaterial and in the constituent material, a binder whose decompositiontemperature is lower than the decomposition temperature of a bindercontained in the constituent material is used, and in the separationpromotion step, the heating step of performing heating at a temperaturehigher than the decomposition temperature of the binder contained in thesupport layer forming material and lower than the decompositiontemperature of the binder contained in the constituent material can beperformed. Such a separation promotion step can be easily performed, andby performing the separation promotion step, the binding force betweenthe ceramic particles by the resin contained in the support layerforming material can be easily made smaller than the binding forcebetween the metal particles by the resin contained in the constituentmaterial.

Further, for example, as the stage 120 and the plate 121, a materialwhich can transmit an electromagnetic wave is used, and as theseparation promotion step, an electromagnetic wave irradiation step ofirradiating the support layer forming material with an electromagneticwave through the stage 120 and the plate 121 (for example, from thelower side) can be performed. Such a separation promotion step can beeasily performed, and by performing the separation promotion step, thebinding force between the ceramic particles by the resin contained inthe support layer forming material can be easily made smaller than thebinding force between the metal particles by the resin contained in theconstituent material.

Incidentally, the separation step may be performed either during theirradiation with an electromagnetic wave or after completion of theirradiation with an electromagnetic wave as long as it is after theirradiation with an electromagnetic wave as the separation promotionstep is started. Examples of the constituent material capable oftransmitting an electromagnetic wave include zirconia and silicondioxide.

According to this embodiment, a titania layer is formed on the plate 121as the support. The binder which is in contact with the titania layer iseasily decomposed by irradiation with an electromagnetic wave, andtherefore, in the separation step, the separation of the second layer S2from the support (plate 121) can be particularly easily performedthrough the titania layer.

The invention is not limited to the above-mentioned embodiments, but canbe realized in various configurations without departing from the gist ofthe invention. For example, the technical features in the embodimentscorresponding to the technical features in the respective formsdescribed in “SUMMARY” may be appropriately replaced or combined inorder to solve part or all of the problems described above or achievepart or all of the advantageous effects described above. Further, thetechnical features may be appropriately deleted unless they aredescribed as essential features in the specification.

What is claimed is:
 1. A three-dimensional shaped article productionmethod for producing a three-dimensional shaped article by stackinglayers, comprising: a first layer formation step of forming a firstlayer above a stage by supplying a first composition being a firstpaste-formed mixture comprising ceramic particles and a binder; a secondlayer formation step of forming a second layer composed of one or morelayers on the first layer by supplying a second composition being asecond paste-formed mixture comprising metal particles and a binder, themetal particles have a sintering temperature lower than the sinteringtemperature of the ceramic particles; and a sintering step of sinteringthe first layer and the second layer is performed by heating the firstlayer and the second layer at a temperature above a sinteringtemperature of the metal particles but below a sintering temperature ofthe ceramic particles.
 2. The three-dimensional shaped articleproduction method according to claim 1, wherein the first layer isformed above the ceramic plate arranged above the stage.
 3. Thethree-dimensional shaped article production method according to claim 1,wherein the first paste-formed mixture and the second paste-formedmixture are supplied in form of a continuous body.
 4. Thethree-dimensional shaped article production method according to claim 1,wherein the first paste-formed mixture and the second paste-formedmixture are produced by heating a solid material at normal temperature.5. The three-dimensional shaped article production method according toclaim 1, wherein the sintering process is carried out using a heatingchamber.
 6. The three-dimensional shaped article production methodaccording to claim 1, wherein the sintering step is performed at atemperature, which is lower than the melting points of the metalparticles and the ceramic particles.
 7. The three-dimensional shapedarticle production method according to claim 1, wherein a binding forcebetween the ceramic particles by the binder contained in the firstcomposition is smaller than a binding force between the metal particlesby the binder contained in the second composition.
 8. Thethree-dimensional shaped article production method according to claim 7,wherein the amount of the binder contained in the first composition issmaller than the amount of the binder contained in the secondcomposition.
 9. The three-dimensional shaped article production methodaccording to claim 1, wherein before the separation step, a separationpromotion step of promoting the separation of the second layer from thestage is performed.
 10. The three-dimensional shaped article productionmethod according to claim 9, wherein the decomposition temperature ofthe binder contained in the first composition is lower than thedecomposition temperature of the binder contained in the secondcomposition, and the separation promotion step is a heating step ofperforming heating at a temperature higher than the decompositiontemperature of the binder contained in the first composition and lowerthan the decomposition temperature of the binder contained in the secondcomposition.
 11. The three-dimensional shaped article production methodaccording to claim 9, wherein the stage is configured to be capable oftransmitting an electromagnetic wave, and the separation promotion stepis an electromagnetic wave irradiation step of irradiating the firstcomposition with an electromagnetic wave through the stage.
 12. Thethree-dimensional shaped article production method according to claim11, wherein a titania layer is formed on the stage.
 13. Thethree-dimensional shaped article production method according to claim 1,wherein the arithmetic average surface roughness Ra of the stage is 5 μmor less.